Apparatus for Interfacing with a Transmission Path

ABSTRACT

A downhole communication apparatus has a signal coupler disposed in an end of a downhole tubular component. The signal coupler has a transceiver portion and a conductor portion. A data conductor integrated into the downhole tubular component is operably connected at a junction to the conductor portion of the signal coupler. A peripheral electronic device is in communication with the conductor portion of the signal coupler, either through an electrical coil wrapped around at least part of the conductor portion of the signal coupler or direct electrical contact with the conductor portion of the signal coupler.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.11/307,406, which was filed Feb. 6, 2007 and is herein incorporated byreference for all that it discloses.

BACKGROUND OF THE INVENTION

The present invention relates to the field of communication along adrill string used for oil and gas exploration, and particularly to thearea of interfacing with a network along a drill string. Communicationwith downhole tools while drilling has been sought for several decades.Several systems in the prior art have disclosed communication withdownhole equipment, and for purposes of understanding they may begrouped into two categories: those that communicate along a wirelinecable, and those that communicate through a tool string

Examples of systems which communicate along a wireline cable may befound in U.S. Pat, No. 5,521,592 to Veneruso (the '592 patent) and U.S.Pat, No. 5,140,318 to Stiner (the '318 patent). The '592 patentdiscloses a method and apparatus for transmitting information, in whichinformation picked up by at least one downhole sensor is conveyed tosurface reception means via a wire connection electrically connectingsaid device to an electrical power supply means on the surface, saidwire connection is inductively coupled firstly with said sensor andsecondly with said reception means. The '318 patent discloses a datatransmission system for use with a logging cable that functions toprovide a more precise transmission of data signal with reducedinterference from higher-powered electrical signals present along theline. The data signals are modulated on a radio frequency carrier, whichis then inductively coupled to the cable jacket or shielding sheath forconduction along the cable.

Examples of systems that communicate through a tool string are disclosedin U.S. Pat. No. 6,679,332 to Vinegar (the '332 patent), and U.S. patentapplication Ser. No. 10/905,894 filed on Jan. 25, 2005 in the name ofHall et. al (The '894 application). The '332 patent discloses anelectronic module that communicates with the surface using the tubingstring and casing as conductors. Induction chokes at the surface anddownhole electrically impede AC flow through the tubing with a resultingvoltage potential useful for power and communication. The '894application discloses a communication element electrically connectedwith a transmission path within a downhole component that inductivelycommunicate with electronic equipment.

BRIEF SUMMARY OF THE INVENTION

A downhole communication apparatus comprises a downhole tubularcomponent having a signal coupler disposed in an end thereof. The signalcoupler has a transceiver portion and a conductor portion. A dataconductor such as a coaxial cable is integrated into the tubularcomponent and is operably connected at a junction to the conductorportion of the signal coupler. Multiple tubular components may be joinedat the ends in a tool string and pass data through the tool stringthrough a system of interconnected signal couplers and data conductors.

A peripheral electronic device is in communication with the conductorportion of the signal coupler, allowing the peripheral electronic deviceto transmit and/or receive data along the data conductor 23 in thetubular component. This communication is achieved in one embodimentthrough an electrical coil wrapped around at least part of the conductorportion of the signal coupler.

In another embodiment the peripheral electronic device comprises adirect electrical connection to a junction between the data coupler andthe conductor portion of the signal coupler. The peripheral electronicdevice is preferably housed in a wall of the tubular component.

The peripheral electronic device may be a sensor or processing elementthat is designed to communicate with surface equipment through itsconnection to the tool string through the signal coupler. The peripheralelectronic device may transmit a signal to the signal coupler on acarrier frequency distinct from a carrier frequency of separate datatransmissions on the tool string.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cut-away diagram of a pin end of a downhole component.

FIG. 2 is a cut-away diagram of a box end of a downhole component.

FIG. 3 is a cut-away diagram of a pin end of a downhole component.

FIG. 4 is a cut-away diagram of a pin end of a downhole component.

FIG. 5 is a diagram of a downhole network.

FIG. 6 is an electronic schematic of a downhole network.

FIG. 7 is a diagram of a possible embodiment of surface equipment in adownhole network.

FIG. 8 is a perspective diagram of an inductive coupler.

FIG. 9 is a cross-sectional diagram of an inductive coupler.

FIG. 10 a-d are diagrams of several embodiments of electrical coils.

FIG. 11 a is a diagram of an embodiment of a connection to an electricalcoil.

FIG. 11 b is a diagram of an alternative embodiment of a connection toan electrical coil.

FIGS. 12 a-c are diagrams of embodiments of connections between ajunction interface and a peripheral electronic device.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

FIG. 1 is a cut-away diagram of a pin end 12 of a downhole tubularcomponent 13. A data transmission system is integrated into the downholecomponent 13. In general, the data transmission system may be adapted totransmit power signals, data signals, and packets. Examples of datatransmission systems that may be compatible with the present inventioninclude those disclosed in U.S. Pat. Nos. 6,670,880 to Hall, et al.6,641,434 to Boyle, et al.; 6,866,306 to Boyle, et al.; and 6,688,396 toFloerke, et al., all of which are herein incorporated by reference forall that they disclose.

In the preferred embodiment the data transmission system is the datatransmission system disclosed in the '880 patent or substantiallysimilar to it and comprises at least one signal coupler 11 electricallyconnected to a data conductor 23. The signal coupler 11 comprises atransceiver portion 160 and a conductor portion 37. The transceiverportion 160 may communicate with a complementary signal coupler coupledto a box end in a second downhole tubular component such as will belater shown in FIG. 2. The conductor portion 37 of the signal coupler 11may be operably connected at a junction 24 to the data conductor 23.

Still referring to FIG. 1, the conductor portion 37 of the signalcoupler 11 may comprise wires, coaxial cables, connectors, lead-ins 14or combinations thereof. A portion of the conductor portion 37 may beselectively removable, such as a lead-in 14 which may be removed forservice or replacement.

The signal coupler 11 is proximate to the pin end 12 of the component13, and the transceiver portion 160 may be in a shoulder 19 of thecomponent 13. The signal coupler 11 may be selected from the groupconsisting of inductive couplers, direct-contact couplers, andcombinations thereof. In the preferred embodiment, the signal coupler isan inductive coupler comprising a coil of wire disposed in a trough ofmagnetically conducting material. A more detailed description of aninductive coupler that may be used with the present invention will begiven in connection with FIG. 4 and FIG. 5.

Still referring to FIG. 1, in this embodiment an electrical coil 20 iswrapped around at least part of the conductor portion 37 of the signalcoupler 11. The electrical coil 20 comprises one or more turns of wire15. The electrical coil 20 may be disposed in a magnetically conductivematerial 16 such as ferrite, nickel, iron or combinations thereof. Amore detailed description of possible embodiments of the electrical coil20 will be given in connection with FIGS. 6 a-d.

Still referring to FIG. 1, a peripheral electronic device 17 associatedwith the downhole component 13 is in communication with the electricalcoil 20. Preferably the peripheral electronic device 17 is in electricalcommunication with the electrical coil through electrical conductor 18,as shown. The peripheral electronic device 17 is in communication withthe data conductor through the electrical coil 20. The electronic device17 may be selected from the group consisting of integrated circuits,pressure sensors, temperature sensors, torque sensors, gyroscopes,inclinometers, accelerometers, chemical sensors, vibration sensors,downhole tools, and combinations thereof. The electronic device 17 maybe located in the wall of the downhole component 13, in the bore of thedownhole component 13, affixed to the outside of the downhole component13, or in other locations in the downhole component 13. The electronicdevice 17 may be adapted to receive signals from and/or transmit signalsto the conductor portion 37 of the signal coupler 11. The signals may bepower signals, data signals, packets, or combinations thereof.

Referring now to FIG. 2 a signal coupler 11 may also be in a box end 22of a downhole tubular component 13. Electrical coil 20 may surround thejunction 24 between lead-in 14 of the conductor portion 37 of the signalcoupler 11 and the data conductor 23. The data conductor 23 may be acoaxial cable with inner 126 and outer 127 conductors. The peripheralelectronic device 17 may be located in the wall 105 of the downholecomponent 13 and electrical conductor 18 may connect the peripheralelectronic device 17 to the electrical coil 20. As previously discussed,electrical coil 20 may comprise at least one turn of wire 15, and may bedisposed in a magnetically conducting material 16. A dielectric material28 such as plastic, epoxy, Teflon® or PEEK® may also be disposed betweenthe junction 24 and the magnetically conducting material 16 toelectrically insulate the electrical coil 20 from the junction 24.

Referring now to FIG. 3, in other embodiments of the invention aperipheral electronic device 17 may be in communication with theconductor portion 37 of the signal coupler 11 through direct electricalcontact. An interface 260 may provide the electrical contact byattaching to both the conductor portion 37 of the signal coupler 11 andelectrical conductor 18 from the electronic device 17. One advantage ofsuch a configuration is less attenuation in a signal transferred fromthe electronic device 17 to the conductor portion 37 or vice versa thanthe attenuation in a similar signal transfer using the embodiment ofFIGS. 1-2.

Referring now to FIG. 4, in other embodiments of the invention theelectronic device 17 may achieve direct electrical communication withthe conductor portion 37 of the signal coupler 11 by coupling to thejunction 24 between the conductor portion 37 and the data conductor 23.

FIG. 5 is a diagram of a downhole network 33 in a downhole tool string201 which may be used with the present invention. A downhole network 33may be used in oil production, geothermal exploration, or oil and gasdrilling. The network 33 comprises various downhole tubular components13 such as those illustrated in FIGS. 1-4, with each tubular component13 comprising an integrated data conductor 23 and at least one signalcoupler 11 in communication with the data conductor 23 and disposed inan end 12, 22 of the tubular component 13.

In-line tubular network nodes 38 may be located at various locationsalong the length of the tool string 201 and operably interconnected byone or many lengths of tubular components 13 linked together. In-linenetwork nodes 38 may be positioned near a drill bit 39 or a bottom holeassembly, so that drilling parameters and monitoring feedback may beaccessible to workers on the surface in real time. Distributed in-linenetwork nodes 38 along the length of the tool string 201 may also bebeneficial to allow the collection and conveyance to the surface of datafrom different depths of a bore. A preferred embodiment of the in-linenetwork nodes 38 is disclosed in U.S. patent application Ser. No.10/613,549 entitled “Link Module for a Downhole Network,” which isherein incorporated by reference.

Preferably the in-line network nodes 38 are a type of tubular component23 and comprise signal couplers 11 that mate to the signal couplers 11in other tubular components 23 to which they link. The in-line networknodes 38 may transmit information up and/or down the tool string 201through the tubular components 23 and other in-line network nodes 38. Agoverning protocol may control the format in which this information istransmitted in addition to media access by the in-line network nodes 38.

In the preferred embodiment of the invention, the downhole network alsocomprises plurality of peripheral electronic devices 17, each peripheraldevice 17 being in communication with the conductor portion 37 of asignal coupler 11 disposed in the end of a tubular component 37. Theseperipheral electronic devices 17 have been described in more detailpreviously (see FIGS. 1-4) and may interface with the conductor portion37 of the signal coupler 11 through an inductive electrical coil 20wrapped around the conductor portion 37 or through a direct electricalconnection to a junction 24 of the data conductor 23 and the conductorportion 37. In alternate embodiments, the downhole network 33 may onlycomprise a plurality of peripheral electronic devices 17 incommunication with the downhole data transmission system.

Referring now to FIG. 6, the in-line network nodes 38 are different fromthe peripheral electronic devices 17 in both their physicalconfiguration with respect to the downhole network 33 and the way theytransmit data on the network 33. Physically, the in-line network nodes38 are essential elements in the path 220 of data transmission along thenetwork 33 and may play an active part in amplifying network datasignals they receive and transmitting new data onto the network 33.Parenthetically, it is important to understand that the path 220 of datatransmission may be physically implemented by a plurality of tubularcomponents 17. Consequently, more than one peripheral. In contrast, theperipheral electronic devices 17 may be characterized as paralleldevices in that they are not directly in the path of data transmissionbetween in-line network nodes 38.

In some embodiments, the peripheral electronic devices 17 may beaddressable on the downhole network 33 and transmit informationaccording to the specified protocol of the network 33. In other morepreferred embodiments, the peripheral electronic devices 17 may utilizethe downhole data transmission system of in-line network nodes 38, dataconductors 23, and signal couplers 11 to transmit data to surfaceequipment 200 while remaining transparent to the in-line network nodes38. One method of accomplishing this entails the modulation of data bythe peripheral electronic devices 17 onto a carrier frequency that isseparate and distinct from the carrier frequency used by the in-linenetwork nodes 38.

Such a system may be advantageous in situations where a peripheralelectronic device 17 such as a sensor may comprise the ability tocommunicate with the surface equipment 200 with a few simple codes. Forexample, a pressure sensor in communication with the conductive medium37 may transmit a single pulse onto the transmission path if there issome increase in the downhole pressure. Such a single pulse may helpworkers adjust parameters in under balanced drilling operations. Twopulses from the pressure sensor may indicate that the downhole pressurehas increased to a level such that a surface crew's safety is in dangerand blow-out preventors may automatically respond. Three pulses mayindicate a decrease in pressure and indicate if drilling mud is beinglost into a subterranean formation. A similar system may be desirable toindicate when a battery supplying power to downhole equipment is low. Inother embodiments, more efficient and/or reliable modulation techniquesmay be used to send signals to the surface.

This type of system may be preferable for communicating sudden changesin downhole parameters and for important messages, such as those dealingwith safety parameters, in a manner that may avoid transmission delaysby avoiding standard network protocols. One way to avoid the standardprotocol of the network 33 is to transmit the signal on a separatefrequency from the frequency on which other network signals aretransmitted. For example, this figure shows samples of two signals 225,226 that are being transmitted along the network path 220.

For convenience in comparing the signals 225, 226, both signals 225, 226are shown to be modulated by dual phase quadrature keying (DPSK), butany modulation scheme may be used according to the needs of specificimplementations of the invention. Signal 225 may represent data beingtransmitted between in-line network nodes 38 and is modulated on adifferent carrier frequency than that of signal 226, which may representdata transmitted by the peripheral electronic devices 17. Preferably thein-line nodes 38 amplify signals transmitted at all frequenciesthroughout the downhole data transmission system.

This embodiment would allow transmissions from the electronic devices 17to be received and interpreted at the surface independent of othernetwork signals. In an embodiment of the invention where multipleelectronic devices 17 are transmitting simple signals on the samechannel, it may be desirable that they use a media access protocol toavoid communication problems.

In some embodiments of the present invention, a signal may be sent tothe electronic device 17 from the surface or from other downhole tools.For example, in order to save power, the electric device 17 may compriseseveral power consumption states, one of which being a sleep mode. Theelectronic device 17 may be in a sleep mode until it receives apredetermined “wakeup” signal 17. This may be desirable in situationswhere drilling or oil production has stopped for a period of time. Alsosome devices 17 may not be as useful in drilling until the devices 17have advanced to a certain depth in the well bore, and may be woken uponreaching a desired depth.

Referring now to FIG. 7, a schematic diagram of one embodiment ofsurface equipment 200 in the downhole network 33 is shown. The surfaceequipment 200 may be connected to the downhole network 33 and receivefrom it an analog signal which is in turn passed through filters 250,251 to recover signal 225 transmitted from the network of in-linenetwork nodes 38 and the signal 226 from the peripheral electronicdevice(s) 117, respectively. The recovered signals 225, 226 may then bepassed through respective modems 252, 253 to recover the digital signalor packet transmitted. Once the digital signal or packet is recovered,it is forwarded to the processing & storage module 254 which may thenprocess and/or store the signal or packet according to design.

FIG. 8 is a detailed diagram of a signal coupler 11. The transceiverportion 160 comprises a wire coil 45 in a trough of magneticallyconducting material 40. A metal ring 41 surrounds the trough ofmagnetically conducting material 40 and one end of the coil 45 has awelded connection 44 to the ring 41. A second end of the coil 45 passesthrough a hole 43 and forms a lead-in 14 in the conductor portion 11 ofthe signal coupler 11 which may be connected to other wires or cables.

FIG. 9 is a cross-sectional diagram of a signal coupler 11 showing wire45 in a trough of magnetically conducting material 40 and a metal ring41 surrounding the trough 40. The magnetically conducting material 40 ispreferably also an electrically insulating material such as a ferrite.Alternatively, an electrically insulating layer 51 may be disposedbetween the ring 41 and the magnetically conducting material 40 and/orbetween the magnetically conducting material 40 and wire 45.

FIGS. 10 a-d are cross-sectional diagrams of several embodiments of waysto achieve communication between the peripheral electronic device 17 andthe lead-in 14 of the conductor portion 37 of the signal coupler 11 aspreviously discussed in connection with FIGS. 1-2. FIG. 10 a shows awire 61 running adjacent to lead-in 14. Wire 61 is preferably proximateto the lead-in 14 such that current flowing in wire 61 will induce acurrent in the lead-in 14 and vice versa.

FIG. 10 b shows a preferred electrical coil 20 wherein multiple turns 62of wire 61 surround lead-in 14. The electrical coil 20 may be surroundedby magnetically conducting material 65. Alternatively, only one turn 63may surround the lead-in 14 as seen in FIG. 10 c or a partial turn 64may partially surround the lead-in 14 as seen in FIG. 10 d. Generally,multiple turns 62 allow more efficient communication between theelectrical coil 20 and the data conductor 23. Although FIGS. 10 a-d allshow a magnetically conductive material in conjunction with wire 61, itis believed that the magnetically conductive material 65 is notrequisite to make an electromagnetic connection with wire 22.

FIG. 11 a and FIG. 11 b are diagrams of two embodiments of anelectromagnetic connection between a peripheral electronic device 17 andan electrical coil 20. In FIG. 11 a, wire 61 surrounds lead-in 14 and isconnected by direct electrical connections 18 to one half of atransformer 71. The other half of transformer may be connected to theperipheral electronic device 17, thus placing the peripheral electronicdevice 17 in communication with the electrical coil 20.

In FIG. 11 b, wire 61 surrounds lead-in 14, and one end 73 of electricalcoil 20 is connected by a direct electrical connection 18 to a capacitor72. The capacitor may be connected to electrical device 17 (not shown)and a second end 74 of electrical coil 20 may be connected by a directelectrical connection 18 to the electrical device 17. The electricaldevice 17 may therefore be in electromagnetic communication withelectrical 20.

The transformer 71 in FIG. 11 a and/or the capacitor 72 in FIG. 11 b maybe used to match the impedance of the electrical coil 20 to theimpedance of the peripheral electronic device 17 (see FIG. 1).Alternatively, the peripheral electronic device 17 may be directlyconnected to both ends of the electrical coil 20 as in FIG. 11 c.

Referring now to FIG. 12 a, in some embodiments the electronic device 17may be in communication with the junction 24 of the data conductor 23and the lead-in 14 of the conductor portion 37 of the signal coupler 11through a transformer 71. An electrical conductor 18 may be connected toone half of the transformer 71 and carry an electrical signal from thejunction 24, in turn inducing a similar electrical signal in the otherhalf of the transformer 71 which may be connected to the peripheralelectronic device 17.

In other embodiments, the peripheral electronic device 17 may be incommunication with the data conductor 23 and the lead-in 14 of theconductor portion 37 of the signal coupler 11 through a capacitor 72 (asshown in FIG. 12 b), or direct electrical contact (as shown in FIG. 12c).

Whereas the present invention has been described in particular relationto the drawings attached hereto, it should be understood that other andfurther modifications apart from those shown or suggested herein, may bemade within the scope and spirit of the present invention.

1. A downhole communication apparatus comprising: a signal coupler proximate an end of a downhole tubular component, the signal coupler comprising a transceiver portion and a conductor portion; a data conductor integrated into the downhole tubular component and electrically connected at a junction interface to the conductor portion of the signal coupler; and a peripheral electronic device in communication with the junction interface; wherein the peripheral electronic device is in communication with the data conductor through the junction interface.
 2. The apparatus of claim 1 wherein the signal coupler is selected from the group consisting of inductive couplers, direct-contact couplers, fiber optic couplers, and combinations thereof.
 3. The apparatus of claim 1 wherein the data conductor is selected from the group consisting of wires, coaxial cables, triaxial cables and combinations thereof.
 4. The apparatus of claim 1 wherein the peripheral electronic device comprises at least one device selected from the group consisting of integrated circuits, pressure sensors, temperature sensors, actuators, piezoelectric devices, torque sensors, gyroscopes, inclinometers, accelerometers, chemical sensors, vibration sensors, processing elements and combinations thereof.
 5. The apparatus of claim 1 wherein the peripheral electronic device is located in the wall of the downhole component, in the bore of the downhole component, affixed to the outside of the downhole component, or combinations thereof.
 6. The apparatus of claim 1 wherein the downhole component is part of a downhole tool string.
 7. The apparatus of claim 6, wherein data is transmitted through the downhole tool string by a system of data conductors and signal couplers in the downhole tool string.
 8. The apparatus of claim 7 wherein the peripheral electronic device is adapted to transmit information on the downhole tool string.
 9. The apparatus of claim 7, wherein the peripheral electronic device transmits data at a carrier frequency distinct from a carrier frequency of separate data transmissions on the tool string.
 10. The apparatus of claim 1, wherein the junction interface comprises a direct electrical connection to the data conductor, the peripheral electronic device, and the conductor portion of the signal coupler.
 11. The apparatus of claim 1, wherein the junction interface is an inductive interface.
 12. The apparatus of claim 11, wherein the inductive interface comprise an electrical coil electrically isolated from the conductor portion of the signal coupler.
 13. The apparatus of claim 12, wherein the electrical coil comprises at least one turn of wire around the conductor portion of the signal coupler.
 14. The apparatus of claim 12, wherein the electrical coil is disposed in a magnetically conductive material.
 15. The apparatus of claim 12, further comprising a dielectric material intermediate the electrical coil and the conductor portion of the signal coupler.
 16. The apparatus of claim 1, wherein the junction interface is located on a lead-in of the conductor portion of the signal coupler.
 17. The apparatus of claim 1, wherein the junction interface is located on a capacitor of the conductor portion of the signal coupler. 